Tap clamp

ABSTRACT

A clamp provides electrical communication between a first conductor and a second conductor. The clamp includes a first housing portion having a first surface, a second surface, a first housing bore, and a cavity, the first housing bore extending along a longitudinal axis. The clamp further includes a clamp member at least partially disposed within the cavity of the first housing portion, the clamp member including a first clamp surface adjacent the second surface of the housing in a facing relationship. The clamp further includes a shaft oriented parallel to the longitudinal axis, the shaft coupling the first housing portion and the clamp member. The clamp further includes a second housing portion movably coupled to the first housing portion by the shaft, the second housing portion including a second housing bore and a second clamp surface, the second housing bore aligned with the longitudinal axis, the second clamp surface adjacent the first surface of the first housing portion in a facing relationship.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of prior-filed, co-pending U.S.patent application Ser. No. 16/323,141, filed on Feb. 4, 2019, which isa 371 of PCT/US2017/045235, filed on Aug. 3, 2017, which claims priorityto Provisional Patent Application No. 62/370,918, filed Aug. 4, 2016,the entire contents of all are hereby incorporated by reference.

BACKGROUND

The present disclosure relates to connectors for electrical conductors,and particularly to conductor tap clamps.

SUMMARY

Conductor tap clamps are hot line connectors for providing electricalcommunication with or tapping a into main power line. In someapplications, conductor tap clamps attach a first conductor to a second,energized, conductor engaged with a transformer.

In one aspect, a clamp for providing electrical communication between afirst conductor and a second conductor includes a first housing portionhaving a first surface, a second surface, a first housing bore, and acavity, the first housing bore extending along a longitudinal axis. Theclamp further includes a clamp member at least partially disposed withinthe cavity of the first housing portion, the clamp member including afirst clamp surface adjacent the second surface of the housing in afacing relationship. The clamp further includes a shaft orientedparallel to the longitudinal axis, the shaft coupling the first housingportion and the clamp member. The clamp further includes a secondhousing portion movably coupled to the first housing portion by theshaft, the second housing portion including a second housing bore and asecond clamp surface, the second housing bore aligned with thelongitudinal axis, the second clamp surface adjacent the first surfaceof the first housing portion in a facing relationship.

In another aspect, a method is provided for providing electricalcommunication between a first conductor and a second conductor. Themethod includes positioning the first conductor between a first surfaceof a first housing portion and a first clamp surface of a second housingportion; positioning the second conductor between a second surface ofthe first housing portion and a second clamp surface of a clamp member;actuating a shaft against a force of a biasing member to increase adistance between the first housing portion and the second housingportion to load the first conductor between the first surface of thefirst housing portion and the first clamp surface of the second housingportion; releasing the shaft to secure the first conductor between thefirst surface of the first housing portion and the first clamp surfaceof the second housing portion; actuating the shaft extending through thefirst housing portion, the second housing portion, and the clamp memberto decrease a distance between the second surface of the first housingportion and the second clamp surface of the clamp member to secure thesecond conductor between the second surface of the first portion of thehousing and the second clamp surface of the clamp member.

In yet another aspect, a clamp for providing electrical communicationbetween a first conductor and a second conductor includes a firsthousing portion, a second housing portion, and a shaft. The firsthousing portion includes a first surface and a first housing boreextending along a longitudinal axis. The second housing portion includesa second surface and a second housing bore aligned with the longitudinalaxis, the second clamp surface adjacent the first clamp surface in afacing relationship to cooperatively form a channel therebetween. Thechannel is configured to receive the first conductor. The shaft isoriented parallel to the longitudinal axis. The shaft couples the firsthousing portion and the second housing portion. The shaft is operable tochange a spacing between the first surface and the second surface.

Other aspects will become apparent by consideration of the detaileddescription and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a clamp engaged with a first conductorand a second conductor.

FIG. 2 is an exploded view of the clamp of FIG. 1.

FIG. 3 is a side view of a main housing.

FIG. 4 is a first end view of the main housing of FIG. 3.

FIG. 5 is a second end view of the main housing of FIG. 3.

FIG. 6 is a side view of a gripper.

FIG. 7 is a perspective view of a keeper.

FIG. 8 is a section view of the clamp of FIG. 1 viewed along section8-8, with the first conductor and second conductor removed.

FIG. 9 is a section view of the clamp of FIG. 1 engaged with the firstconductor and viewed along section 9-9.

FIG. 10 is a section view of the clamp of FIG. 1 engaged with the firstconductor and the second conductor and viewed along section 9-9.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understoodthat the disclosure is not limited in its application to the details ofconstruction and the arrangement of components set forth in thefollowing description or illustrated in the following drawings. Thedisclosure is capable of other embodiments and of being practiced or ofbeing carried out in various ways. Also, it is to be understood that thephraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. The terms “mounted,” “connected” and“coupled” are used broadly and encompass both direct and indirectmounting, connecting and coupling. Further, “connected” and “coupled”are not restricted to physical or mechanical connections or couplings,and can include electrical or hydraulic connections or couplings,whether direct or indirect. Also, electronic communications andnotifications may be performed using any known means including directconnections, wireless connections, etc.

FIG. 1 illustrates a clamp 10 for electrically connecting a firstconductor 14 and a second conductor 18. In the illustrated embodiment,the clamp 10 is a tap clamp or a hot line clamp, and the clamp 10includes a first housing portion or main housing 22, a second housingportion or gripper 26, a clamp member or keeper 30, a linear actuator34, a resilient member 38 (FIG. 2), and a nut 42 (FIG. 2).

As shown in FIGS. 2-5 and 8, the main housing 22 includes a first boreor main housing bore 46, a first channel 50 (FIG. 4), a second channel54 (FIG. 5), a first surface 58, and a second surface 62. In theillustrated embodiment, the main housing 22 is made from a conductivematerial; in other embodiments, only a portion of the main housing 22 ismade from a conductive material. As shown in FIG. 3, the main housingbore 46 extends along a longitudinal axis 66.

As shown in FIG. 4, the first channel 50 is adjacent the housing bore 46and aligned along the longitudinal axis 66. In the illustratedembodiment, the first channel 50 is substantially U-shaped, although thefirst channel may have a different shape in other embodiments. The firstchannel 50 is positioned between a first upper surface 86, a secondupper surface 90, and a wall 92. In the illustrated embodiment, a firsttrack 78 and a second track 82 extend along the sides of the firstchannel 50, adjacent the upper surfaces 86, 90. The first track 78 andthe second track 82 are spaced apart laterally from one another acrossthe longitudinal axis 66 and extend along a length of the first channel50, parallel to the longitudinal axis 66. The first track 78 ispositioned opposite the first upper surface 86 and the second track 82is positioned opposite the second upper surface 90. In otherembodiments, the main housing 22 may include fewer or more tracks, andthe tracks may be positioned in a different manner.

As best shown in FIG. 8, the second channel 54 is spaced from the firstchannel 50 and extends in a direction generally parallel to thelongitudinal axis 66. In the illustrated embodiment, the second channel54 has a generally circular shape and extends between a rear wall 110and an end surface 112 (FIG. 3) that is oriented at an angle relative tothe longitudinal axis 66. As discussed in further detail below, thesecond channel 54 is sized to receive at least a portion of the gripper26.

Referring again to FIG. 5, in the illustrated embodiment the firstsurface 58 includes an upper portion 114 and a lower portion 118 and ispositioned adjacent the second channel 54. The upper portion 114 isformed as a bore extending along a first axis 126 that is substantiallyperpendicular to the longitudinal axis 66. The upper portion 114 and thelower portion 118 are aligned along the first axis 126. The upperportion 114 and the lower portion 118 are sized to receive the firstconductor 14 (FIG. 1). In other embodiments, the first surface 58 may beformed in another shape, such as a partially curved or non-enclosedsurface.

As shown in FIG. 3, the second surface 62 is positioned between aninclined surface 130 of the main housing 22 and the upper surfaces 86,90. The second surface 62 is a curved surface and is sized to receive aportion of the second conductor 18 (FIG. 1). In the illustratedembodiment, the second surface 62 extends along a direction that issubstantially perpendicular to both the first surface 58 and thelongitudinal axis 66, and partially defines a passage for the secondconductor 18 (FIG. 10). In other constructions, the second surface 62,the first surface 58, and the longitudinal axis 66 may have a differentgeometric relationship. For example, the first surface 58, the secondsurface 62, and the longitudinal axis 66 may be formed at an anglerelative to one another, but not mutually perpendicular.

As shown in FIGS. 6 and 8, the gripper 26 includes an aperture 134, afirst portion 138, a surface 142 (FIG. 6), a second portion 146, and agripper channel or cavity 150 (FIG. 8). The aperture 134 is alignedalong the longitudinal axis 66. In the illustrated embodiment, thesurface 142 (FIG. 2) is curved and cooperates with the first surface 58of the main housing 22 (FIG. 2) to form a passage for receiving thefirst conductor 14. The second portion 146 may have a profile thatcomplements the profile of the housing end surface 112. For example, inthe illustrated embodiment the second portion 146 includes peripheralsurfaces 162 that are inclined to mate with the end surface 112 of thesecond channel 54.

As shown in FIG. 8, the cavity 150 is aligned with the aperture 134along the longitudinal axis 66. The cavity 150 receives the nut 42. Arear wall 170 of the cavity 150 forms a seat abutting the nut 42 andprovides a reaction surface. In the illustrated embodiment, the nut 42has a non-circular cross section. The cavity 150 may have a non-circularcross section in a similar shape as the nut 42 so that the nut 42 doesnot rotate with respect to the gripper 26. The nut 42 is secured to(e.g. by in-casting, peening, or welding) or axially fixed with respectto the gripper 26. In other embodiments, the nut may have a circular orround cross-section.

As shown in FIG. 7, the keeper 30 includes a first portion 174 and asecond portion 178 coupled to the first portion 174. The first portion174 of the keeper 30 includes a clamp surface or keeper surface 182, afirst slide portion 186, and a second slide portion 190. The keepersurface 182 extends laterally relative to the axis 66 (FIG. 8). Thekeeper surface 182 is a curved surface and is sized to engage a portionof the second conductor 18 (FIG. 1). The first slide portion 186 and thesecond slide portion 190 are spaced apart laterally and orientedperpendicular to the keeper surface 182. In the illustrated embodiment,the first slide portion 186 and the second slide portion 190 have flatlower surfaces. As shown in FIG. 2, the first slide portion 186 and thesecond slide portion 190 engage the first upper surface 86 and thesecond upper surface 90 of the main housing 22, respectively.

Referring again to FIG. 7, in the illustrated embodiment, the secondportion 178 includes an opening 194, a first guide 198 and a secondguide 202. The opening 194 is aligned along the longitudinal axis 66(FIG. 8). The first guide 198 and the second guide 202 are laterallyspaced apart and protrude from opposite sides of the second portion 178.In the illustrated embodiment, the first guide 198 and the second guide202 are substantially triangular. The first guide 198 is disposed withinthe first track 78 (FIG. 9) and the second guide 202 is disposed withinthe second track 82, respectively, of the main housing 22. In otherembodiments, the guides 198, 202 may be formed in a different manner ormay engage the main housing 22 in a different manner. In otherembodiments, the keeper 30 may engage the main housing 22 in a differentmanner.

As shown in FIG. 2, the linear actuator 34 includes a shaft 210 and aflange 214. The shaft 210 may include a threaded portion 218 and anon-threaded portion 222. The flange 214 is positioned at one end of theshaft 210. In the illustrated embodiment, the actuator 34 is an eyebolt,and the flange 214 is positioned between the threaded portion 218 and aneye stem 206. In the illustrated embodiment, the flange 214 is circularand sized to be at least partially received by the first channel 50 ofthe main housing 22 (FIG. 10).

As shown in FIG. 2, the resilient member 38 in the present embodiment isa coiled compression spring. The coils of the compression spring definean opening 230 therebetween. The resilient member 38 is at leastpartially positioned within the first channel 50 of the main housing 22.

FIG. 8 shows a section view of the clamp 10. The opening 194 of thekeeper 30, the opening 230 of the resilient member 38, the main housingbore 46, and the aperture 134 of the gripper 26 are aligned along thelongitudinal axis 66, and the linear actuator 34 extends therethrough.The opening 194 of the keeper 30 and the resilient member 38 aredisposed along the non-threaded portion 222 of the shaft 210. Theresilient member 38 is seated against a first wall 196 of the keeper 30and abuts the wall 92 of the first channel 50 of the main housing 22.The flange 214 abuts a second surface 197 of the second portion 178 ofthe keeper 30. The main housing bore 46 and the aperture 134 aredisposed along the threaded portion 218 of the shaft 210. The threadedportion 218 is threadably engaged with the nut 42 disposed within thecavity 150 of the gripper 26. The nut 42 is seated against the rear wall170 of the cavity 150 of the gripper 26, so that the linear actuator 34and the gripper 26 move together along the axis 66.

As shown in FIG. 2, the first surface 58 of the main housing 22 and thesurface 142 of the gripper 26 are aligned in a facing relationship toco-operatively define a first channel 234 (FIG. 9) therebetweenextending along the first axis 126. Because the gripper 26 is movablerelative to the main housing 22, the first channel 234 has a variablewidth to accommodate a variety of sizes of conductor. As shown in FIG.9, the second surface 62 of the main housing 22 and the keeper surface182 of the keeper 30 are aligned in a facing relationship toco-operatively define a second channel 242 therebetween extending alonga second axis 238. Because the keeper 30 is movable relative to the mainhousing 22, the second channel 242 has a variable width to accommodate avariety of sizes of conductor.

Referring to FIG. 8, before installing the first conductor 14, anoperator may immobilize the main housing 22 and push the linear actuator34 against the bias of the resilient member 38 in a first direction 246along the longitudinal axis 66. The flange 214 engages the secondportion 178 of the keeper 30 and pushes the keeper 30 towards the mainhousing 22. As the keeper 30 slides towards the main housing 22, thefirst guide 198 (FIG. 7) and the second guide 202 of the keeper 30travel along the first track 78 and the second track 82, respectively,of the main housing 22. As the linear actuator 34 is pushed in the firstdirection 246, the gripper 26 moves away from the main housing 22,creating a space between the main housing 22 and the gripper 26.

As shown in FIG. 9, the operator aligns the first surface 58 of the mainhousing 22 with the surface 142 of the gripper 26 along the first axis126 to form the first channel 234 therebetween. The operator theninserts the first conductor 14 into the first channel 234. The operatorreleases the linear actuator 34, and the resilient member 38 urges thekeeper 30 away from the main housing 22 in a second direction 250 alongthe longitudinal axis 66. As the resilient member 38 urges the keeper 30away from the main housing 22, the gripper 26 is pulled towards the mainhousing 22 to hold the first conductor 14 within the first channel 234.

To insert the second conductor 18, the operator aligns the secondconductor 18 along the inclined surface 130 of the main housing 22 andslides the second conductor 18 into the second channel 242 definedbetween the keeper surface 182 and the second surface 62. The operatorthreads the linear actuator 34 relative to the nut 42 (FIG. 8), pullingthe keeper 30 and the gripper 26 towards the main housing 22 anddecreasing a distance between the keeper surface 182 and the secondsurface 62 of the main housing 22. As the keeper 30 slides towards themain housing 22, the first guide 198 and the second guide 202 of thekeeper 30 travel along the first track 78 and the second track 82,respectively, of the main housing 22 (FIGS. 9 and 10). The positioningof the guides 198, 202 of the keeper 30 within the tracks 78, 82 of themain housing 22 prevents the keeper 30 from rotating with respect to themain housing 22 as the linear actuator 34 is rotated, and maintains thekeeper surface 182 in a parallel orientation with respect to the secondsurface 62 of the main housing 22. The rotation of the linear actuator34 compresses the resilient member 38, thereby also decreasing adistance between the main housing 22 and the gripper 26 until the firstconductor 14 and the second conductor 18 are held tightly by the clamp10 as shown in FIG. 10.

In the embodiment shown in FIG. 10, the second conductor 18 is a liveconductor. An electric current travels from the second conductor 18through the main housing 22 and into the first conductor 14.

Although some aspects have been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe scope and spirit of one or more independent aspects as described.Various features and advantages are set forth in the following claims.

What is claimed is:
 1. A clamp for providing electrical communicationbetween a first conductor and a second conductor, the clamp comprising:a first housing portion including a first surface and a second surface;a clamp member including a first clamp surface adjacent the secondsurface of the first housing portion; a shaft coupling the first housingportion and the clamp member; and a second housing portion movablycoupled to the first housing portion by the shaft, the second housingportion including a second clamp surface adjacent the first surface,wherein the shaft is movable in a first direction to secure the firstconductor between the first surface of the first housing portion and thesecond clamp surface, and wherein the shaft is movable in a seconddirection to move the clamp member relative to the first housing portionto secure the second conductor between the second surface of the firsthousing portion and the first clamp surface.
 2. The clamp of claim 1,wherein the first surface of the first housing portion and the secondclamp surface of the second housing portion cooperatively form a channeltherebetween, the channel configured to receive the first conductor. 3.The clamp of claim 2, wherein the first surface of the first housingportion is an internal surface of a cylindrical through-opening and thesecond clamp surface of the second housing portion is curved.
 4. Theclamp of claim 2, wherein the channel is oriented substantiallyperpendicular to the shaft.
 5. The clamp of claim 1, wherein actuationof the shaft changes a spacing between the first surface of the firsthousing portion and the second clamp surface of the second housingportion.
 6. The clamp of claim 1, wherein the first clamp surface ispositioned on a first portion of the clamp member, the clamp memberincluding a second portion having an internal hole receiving the shaft.7. The clamp of claim 1, wherein the second surface of the first housingportion and the first clamp surface of the clamp member cooperativelyform at least a portion of a channel therebetween, the channelconfigured to receive the second conductor.
 8. The clamp of claim 7,wherein the second surface of the first housing portion and the firstclamp surface of the clamp member form curved surfaces of the channel.9. The clamp of claim 1, further comprising a resilient member exertinga biasing force on the shaft and biasing the second housing portiontoward the first housing portion.
 10. The clamp of claim 1, furthercomprising a threaded member threadedly engaging the shaft, and whereinthe clamp member, the first housing portion, and the second housingportion are secured between the threaded member and a flange of theshaft.
 11. A clamp for providing electrical communication between afirst conductor and a second conductor, the clamp comprising: a firsthousing portion including a first surface, a second surface, and a firsthousing bore; a clamp member movably coupled to the first housingportion, the clamp member including a first clamp surface adjacent thesecond surface of the first housing portion; and a second housingportion movably coupled to the first housing portion, the second housingportion including a second housing bore and a second clamp surface, thesecond housing bore aligned with the first housing bore, the secondclamp surface adjacent the first surface of the first housing portion,the second housing portion movable in one direction to secure the firstconductor and clamp member is movable in a second direction to securethe second conductor.
 12. The clamp of claim 11, further comprising ashaft that is oriented parallel to the first housing bore, the shaftcoupling the first housing portion and the clamp member, and the secondhousing portion and the first housing portion.
 13. The clamp of claim12, further comprising a resilient member exerting a biasing force onthe shaft and biasing the second housing portion toward the firsthousing portion.
 14. The clamp of claim 12, wherein the first clampsurface is positioned on a first portion of the clamp member, the clampmember including a second portion having an internal hole receiving theshaft.
 15. The clamp of claim 11, wherein the second surface of thefirst housing portion and the first clamp surface of the clamp membercooperatively form at least a portion of a channel therebetween, thechannel configured to receive the second conductor.
 16. The clamp ofclaim 11, wherein the first surface of the first housing portion and thesecond clamp surface of the second housing portion cooperatively form achannel therebetween, the channel configured to receive the firstconductor.
 17. A clamp for providing electrical communication between afirst conductor and a second conductor, the clamp comprising: a firsthousing portion including a first surface and a first housing bore; asecond housing portion including a second surface and a second housingbore aligned with the first housing bore, the first surface and thesecond surface configured to engage the first conductor disposed betweenthe first housing portion and the second housing portion; a clamp memberpositioned proximate the first housing portion and configured to securethe second conductor against the first housing portion; and a shaftcoupling the first housing portion and the second housing portion, theshaft being slideable to adjust a spacing between the first surface andthe second surface and the shaft being threadable to adjust a spacingbetween the clamp member and the first housing portion.
 18. The clamp ofclaim 17, wherein the shaft oriented orthogonal with respect to an axisof the first conductor and orthogonal with respect to an axis of thesecond conductor.
 19. The clamp of claim 17, wherein the first surfaceof the first housing portion is an internal surface of a cylindricalthrough-opening and the second surface of the second housing portion iscurved.
 20. The clamp of claim 17, further comprising a resilient memberexerting a biasing force on the shaft and biasing the second housingportion toward the first housing portion.